My very first no run thread! Hooray!! (Edit: My first engine build! Hooray!!!)

[truckinwagen]

I got mine from headbolts.com

fast service and good shipping etc...

[Jettagli16v]

Done.
They ship USPS, so I guess 3-5 working days?

I hope they actually have them in stock,
not just take the money and order them.

I figure, why go through all this and not replace rod bolts...

I talked to my friend, who advised me to buy the 3 notch gasket now and measure the protrusion later and hope we are right.
Probably a safe assumption, as I am pulling a 3 notch off, and the car ran great before.

Damn, im gonna end up spending a grand on this thing,
but it will run Right!!
The worst part is the wait..

Off to Gasketstogo!!!!

-Brad

[Jettagli16v]

this is frustrating!
I dont have a microphone for my computer!
I can call the guy (@gasketstogo.com), and he says "Hello?"
but he wont respond in the chat.
(who knows if I am even working the damn program right!)
Ill have to just email him and go from there!

-Brad

[Jettagli16v]

Well,
I have established contact with John at gasketstogo.
I am ordering a 1.61mm (= 3 notch)
gasket in MLS....


let the good times roll!
-brad

[jtanguay]

i don't remember my rod bolts being $100 even from the dealer.  i wish i could find the receipt... they are pretty damn close to that figure though!!!  which is why i'm kicking myself for not waiting and going with ARP  

[Jettagli16v]

I could get the bolts at the dealership for $120,
and online for like $60-70,
but still had to go ARP....

John @g.t.g. will be making my gasket this week or next,
and shipping it straightaway!

Then ill really have something!!
-Brad

[jtanguay]

for the price of those custom gaskets i'd rather just use a piece of rubber to block that hole.  either way it doesn't really see any real pressure.  but from what i've been hearing, AAZ gaskets can range from $30-60 so its a toss up really.

if only there was a higher demand for these special gaskets, the price could come down.

[Jettagli16v]

I was of the impression that because I have a mechanical head and block,
I need to plug a drain (albeit an unnecessary one)
in the head and block.
I would rather not permanently modify the head or block, if it is possible.
Also, there is a slight decrease in compression due to larger bore?
I spent weeks reading 53Willys, ZukGod1, and as many of the headgasket threads I could find with mech head and block.

I hope that is accurate.
Otherwise I just wasted $120!

-Brad

[jtanguay]

i forget who did it, but someone put rubber to block the oil & coolant port, and was successful.

[Jettagli16v]

I would totally rather spend $150 and be sure,
than $40-50 (AAZ) and some permatex and crossed fingers.
Based on the way 53Willys had to torque that thing down,
I will never have a headgasket concern again!!

Now I have a month to get Everything else in order.
I want to be in a position to get the HG, slap it together and get back to Driving!
So far all I have done is polish the first half of my Downpipe!
(but it looks niiiice!)

-Brad

[Jettagli16v]

Here is the pile of parts I currently have in my dining room:
Totally gone through head, guaranteed true w/ new exhaust guides and valve stem seals,
Injectors rebuilt by Giles,
ARP Head studs
ARP con rod bolts,
New oil pump, Pan gasket with windage, rubber valve cover conversion,
Piston rings and rod bearings
Just waiting on the headgasket,
and then on to assembly!

Keep your fingers crossed for me though,
Im certainly not out of the woods yet!
-Brad

[Jettagli16v]

HOORAY! HOORAY!
It is a glorious day when John from gasketstogo.com sends you an email and tells you that your MLS headgasket is done and will leave Thailand tomorrow!
(but then it is also my 10-14 day notice to get back to work!! I gotta get it moved to the shop for assembly...)
I really miss my car!!

-Brad

[Jettagli16v]

Update:
Received the gasket form John two weeks ago,
to find he accidentally made one for 1.9 AAZ....

He was really really cool about it and offered to refund my money right then,
but I opted to wait for the proper gasket...
Other than that, I am chomping at the bit to re-assemble!

-Brad

[Jettagli16v]

The right gasket arrived last week,
and its time to assemble!

Long day today.
did not get started until 7Pm,
but I got the block surface cleaned,
and used a set of honing stones and then a ball hone to smooth out the cylinders.
Cleaned everything a million times,
checked my compression ring gap:
#2 was within spec, and the others were not to the wear limit, (good sign)
And checked the ring play and all were within spec.

Tomorrow, I am shooting to at least have the head on the block.
Wish me luck!!!
-Brad

[Jettagli16v]

Update:
(If anyone is listening)

I got a good chunk of work knocked out on the engine rebuild between Thurs, fri, and sun after work.
So far:
-Honed cylinders & Cleaned block surface
-Measured ring gap with compression ring: no cylinders yet to the wear limit
-Installed a full set of piston rings
-Installed a full set of rod bearings
-Pistons & Rods installed, torqued.
-Measured piston protrusion on cyls 1+4: All in the 3 notch range (measured at 4 places on the piston)
-Installed AAZ Pil pan gasket & Windage pan
-Installed new HD oil pump (Myke_W)
-Installed ARP racing head studs

Head prep:
-Cylinder head decked, new exhaust guides and all valve seals replaced.
-Installed new Bosch glow plugs
-Installed Giles rebuilt injectors
-Intake manifold installed
-new studs installed for rubber valve cover gasket conversion

I took 2-3 pictures, but am too tired to post them now..

Late this week
(Thursday / friday, my weekend)
Ill be installing the headgasket (MLS)
and head,
and then hopefully, have a running turbo diesel again!

Question of the day:
How do you go about breaking in your rings?
I was wondering about disconnecting the LDA and turbo outlet hose,
and running normally aspirated for 2 tanks of gas (~800 mi)
to break everything in easily...
Too much? too little?

Thanks,
-Brad